Flexible phase change material composite for thermal management systems

Abstract

A thermal management composite, comprising a phase change material within a carbon or graphite matrix. The matrix is coated with a polymer coating to improve flexibility. The matrix can be a molded carbon or graphite material or a carbon or graphite cloth.

What is claimed is: 
     
       1. A thermal management composite, comprising:
 a carbon or graphite cloth matrix including knitted or woven carbon or graphite fibers; 
 a phase change material disposed in voids between the fibers or bundles of the fibers; and 
 a polymer coating on at least one surface of the composite, wherein the polymer coating comprises graphite dispersed therein. 
 
     
     
       2. The composite of  claim 1 , wherein the matrix is wrapped around one or more battery cells. 
     
     
       3. The composite of  claim 1 , wherein the carbon or graphite matrix is mixed or impregnated with each of the phase change material and a polymer material. 
     
     
       4. The composite of  claim 1 , wherein the phase change material comprises a wax. 
     
     
       5. The composite of  claim 1 , further comprising a microencapsulated phase change material. 
     
     
       6. The composite of  claim 5 , wherein the phase change material comprises a microencapsulated wax. 
     
     
       7. The composite of  claim 1 , further comprising the polymer coating on each of a top side and a bottom side of the matrix. 
     
     
       8. The composite of  claim 1 , wherein the matrix is flexible. 
     
     
       9. A method of making a thermal management composite, the method comprising:
 impregnating a carbon or graphite matrix comprising knitted or woven carbon or graphite fibers with a phase change material; and 
 coating at least one side of the impregnated matrix with a polymer coating wherein the polymer coating comprises graphite dispersed therein. 
 
     
     
       10. The method of  claim 9 , further comprising dip coating or spray coating the matrix with the phase change material and/or the polymer coating. 
     
     
       11. The method of  claim 9 , wherein the coating comprises a coating polymer material mixed with carbon or graphite powder or fibers. 
     
     
       12. The method of  claim 11 , further comprising dip coating or spray coating the matrix with the phase change material and/or the polymer coating. 
     
     
       13. A thermal management composite, comprising:
 a flexible carbon or graphite cloth matrix of carbon or graphite fibers, wherein the cloth is knitted or woven from the carbon or graphite fibers or bundles of the carbon or graphite fibers; and 
 a phase change material disposed in voids between the fibers or the bundles of the fibers; and a polymer coating on at least one surface of the composite, wherein the polymer coating comprises graphite dispersed therein. 
 
     
     
       14. The composite of  claim 13 , wherein the flexible cloth matrix is configured to wrap around one or more battery cells. 
     
     
       15. The composite of  claim 13 , wherein the phase change material comprises a microencapsulated wax.